Combing device for a circular comb and method for the manufacture of the combing device

ABSTRACT

Embodiments of the invention relate to a combing device for a combing machine exhibiting at least a circular comb and at least a top comb, with a number of comb teeth serving to engage in a fiber fleece and arranged side by side in a direction approximately vertical to the direction of combing, with the combing device exhibiting at least one comb element with at least two, three, or more comb teeth made in one piece and arranged side by side in the direction extending vertically to the direction of combing.

RELATED APPLICATIONS

This application is based on and claims priority to German Patent Application No. 102006009732.7, entitled “Kämmeinrichtung für einen Rundkamm und Verfahren zur Herstellung der Kämmeinrichtung”, and filed on Mar. 2, 2006. That application is fully incorporated herein by this reference. A certified English translation of the German priority application is also provided in an accompanying document.

TECHNICAL FIELD

Embodiments of the invention relate to a combing device for a combing machine, having at least one circular comb and at least one top comb and having a number of comb teeth serving to engage in a fiber fleece and arranged side by side in a direction that is approximately vertical to the direction of combing.

BACKGROUND

Combing machines often serve to refine yarns manufactured from textile fibers. In the manufacture of yarns, it is typically arranged between the carding and the stretching station. The main tasks of the combing machine consist of the elimination of short fibers from the card slivers produced by the carding station, i.e. the improvement of the stack of the raw fiber material as well as the improvement of the parallelization of the individual fibers of the fiber fleece supplied by the carding station in the form of the card sliver. As a secondary effect, further cleaning of the fiber fleece is achieved in the combing machine by the elimination of neps and seed particles. To achieve the improvements of the fiber fleece described above, a fiber tuft of the fiber fleece, which is fed from a supply cylinder and held by means of a gripper, is combed through by a circular comb in the combing machine, which rotates about a fixed axis; said fiber tuft is then soldered with an already combed combing fleece and is then torn off of the fiber fleece yet to be combed due to the engagement of a top comb in the tuft which has been combed by the circular comb and the simultaneous removal of the combing fleece from the supply cylinder. The desired improvement of the parallelism of the individual fibers of the fiber fleece as well as the improvement of the stack by means of elimination of short fibers is effected by the interaction of the circular comb and the top comb.

The top comb of conventional combing machines is typically composed of a support element in the form of a sheet metal strip and comb teeth soldered thereto in the form of flat needles. When the combing machine is operated at high operating speeds and when such top combs are used, it is impossible to achieve a parallelization of the individual fibers of the fiber fleece that satisfies the requirements of high quality yarns, while at the same time heavy soiling of the top comb is observed, which makes frequent cleaning necessary. In order to eliminate this deficiency, German Patent No. 195 31 605 proposes a further development of conventional top combs, characterized by the comb teeth of the top comb as well as the comb teeth of the circular comb having the form of saw tooth wire sections with, respectively, at least one saw tooth exhibiting tooth flanks extending essentially parallel to the direction of combing and a tooth face extending vertically thereto. Here, the saw tooth wire sections used for the manufacture of the top comb as well as the saw tooth wire sections used for the manufacture of the circular tooth may consist, respectively, of a base and a reed joined thereto and exhibiting the at least one saw tooth, with the dimensions of the base being greater in a direction extending essentially vertically to the direction of combing than the dimensions of the reed in this direction, so as to provide the combing spaces enabling the passage of the fibers through the respective comb elements during the combing process.

For the manufacture of such combing devices, a wire-shaped basic raw material is first subjected to a cold rolling process in order to create a wire profile forming the base area and the reed area of the saw tooth wire sections. In a next manufacturing step, the saw teeth are extracted from the profile wire using a punching process. From the saw tooth wire thus obtained, saw tooth wire sections are cut off to such a length that is required for the manufacture of a top comb or a circular comb. The saw tooth wire sections are then combined into bundles and attached on a suitable support element. Following the extraction of the saw teeth from the reed section of the profile wire, the saw teeth can be subjected to a hardening process, such as, e.g., a laser or flame hardening process.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will be described by way of exemplary embodiments, but not limitations, illustrated in the accompanying drawings in which like references denote similar elements, and in which:

FIG. 1 illustrates a method for the manufacture of comb elements, which is suitable for the manufacture of top combs, in accordance with various embodiments of the invention; and

FIG. 2 illustrates a flowchart view of operations for manufacturing comb elements, in accordance with various embodiments of the invention.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Illustrative embodiments of the present invention include, but are not limited to a combing device for a combing machine exhibiting at least a circular comb and at least a top comb, with a number of comb teeth serving to engage in a fiber fleece and arranged side by side in a direction approximately vertical to the direction of combing, with the combing device exhibiting at least one comb element with at least two, three, or more comb teeth made in one piece and arranged side by side in the direction extending vertically to the direction of combing.

Various aspects of the illustrative embodiments will be described using terms commonly employed by those skilled in the art to convey the substance of their work to others skilled in the art. However, it will be apparent to those skilled in the art that alternate embodiments may be practiced with only some of the described aspects. For purposes of explanation, specific numbers, materials, and configurations are set forth in order to provide a thorough understanding of the illustrative embodiments. However, it will be apparent to one skilled in the art that alternate embodiments may be practiced without the specific details. In other instances, well-known features are omitted or simplified in order not to obscure the illustrative embodiments.

Further, various operations will be described as multiple discrete operations, in turn, in a manner that is most helpful in understanding the illustrative embodiments; however, the order of description should not be construed as to imply that these operations are necessarily order dependent. In particular, these operations need not be performed in the order of presentation.

The phrase “in one embodiment” is used repeatedly. The phrase generally does not refer to the same embodiment; however, it may. The terms “comprising,” “having,” and “including” are synonymous, unless the context dictates otherwise. The phrase “A/B” means “A or B”. The phrase “A and/or B” means “(A), (B), or (A and B)”. The phrase “at least one of A, B and C” means “(A), (B), (C), (A and B), (A and C), (B and C) or (A, B and C)”. The phrase “(A) B” means “(B) or (A B)”, that is, A is optional.

As it can be gathered from the above explanation of conventional combing devices for top comb machines, their manufacture may involve significant costs. In view of these technical problems and costs, embodiments of the invention provide a combing device for combing machines, with said combing device being especially easy to manufacture. In various embodiments, the combing device may allow the production of a high quality carded and combed (top) sliver or a high quality combing machine ribbon, using, in one embodiment, high machine running times and high operating speeds, as well as providing a method for the manufacture of such combing devices. Also, according to embodiments of the invention, the combing device may exhibit at least one comb element with at least two, three, or more comb teeth made in one piece and arranged side by side in the direction extending vertically to the direction of combing.

Embodiments of the invention are based on the insight that problems encountered in the manufacture of conventional combing devices for combing machines are primarily due to the fact that their comb teeth are formed by means of a multitude of individual parts to be arranged side by side, such as, e.g., saw tooth wire sections, with the additional requirement that these individual parts have to be manufactured beforehand using a required manufacturing process (cold rolling, punching, hardening).

These problems may be eliminated in the manufacture of the combing device in accordance with embodiments of the invention because two, three, or more (in some embodiments, 20, 30, or more) of the comb teeth arranged side by side in the direction extending vertically to the direction of combing may be combined into a comb element made in one piece such that the process of bundling and attaching of the comb teeth to a support element can be significantly simplified. In addition, it is possible to produce the comb elements of combing devices in accordance with embodiments of the invention in a particularly simple way because the preparatory activities to obtain the profile wire may be eliminated. Thus, a basic raw material, which exhibits the desired material properties without having to undergo an additional hardening process, can be used for the manufacture of the comb elements.

As can be gathered from the explanations regarding conventional combing machines, it has been shown to be advantageous if at least one of the comb teeth has a saw tooth-shaped design with two tooth flanks extending parallel to the direction of combing and a tooth face connecting the tooth flanks and extending approximately vertically thereto, with the transitions between the tooth flanks and tooth face possibly being rounded.

With conventional combing devices, the fixing of the comb teeth may be achieved via special fastening elements to which the comb teeth have to be attached. With the comb elements of combing devices according to embodiments of the invention, it is also possible for the fastening area designed for the attachment of the comb element to the combing machine to be made in one piece with the comb teeth.

Especially when using combing devices in accordance with embodiments of the invention in the form of circular combs for a combing machine, but also when using combing devices in accordance with embodiments of the invention in the form of top combs for a combing machine, it may be advantageous, in order to obtain an especially desirable combing effect, for the comb element to exhibit at least two, three, or more comb teeth arranged in series. When using combing devices, in accordance with embodiments of the invention in the form of top combs, the tips of the comb teeth arranged side by side in the direction extending vertically to the direction of combing may be expeditiously arranged approximately on a straight line extending vertically to the direction of combing. The tips of the comb teeth arranged in series in the direction of combing may be arranged, when using combing devices in accordance with embodiments of the invention in the form of circular combs, approximately on a circular arc, the center of which may fall on the fixed axis rotated about by the circular comb.

To manufacture the combing devices in accordance with various embodiments of the invention, it may not be necessary to first subject the base raw material to a cold rolling process and then a punching process, as is often done when manufacturing conventional combing devices. For this reason, the comb elements of combing devices, in accordance with embodiments of the invention, may be made at least in part from high-alloyed steel, such as stainless chrome nickel steel, the cold forming properties of which would no longer be sufficient for the manufacture of profile wires.

In some embodiments, a comb element may be characterized in that it exhibits at least two, three, or more (in one embodiment, 20, 30 or more) comb teeth made in one piece and arranged side by side in the direction extending vertically to the direction of combing.

A top comb, according to embodiments of the invention, obtained by using respective comb elements, may be characterized in that it may exhibit two, three, or more comb teeth made in one piece, the tooth tips of which may be arranged on a straight line extending approximately vertically to the direction of combing.

A circular comb manufactured by using comb elements in accordance with embodiments of the invention may comprise both two, three, or more comb teeth made in one piece and arranged side by side in a direction extending vertically to the direction of combing, as well as two, three, or more comb teeth made in one piece and arranged in series in the direction of combing. It is possible, both for the manufacture of top combs and the manufacture of circular combs, in accordance with embodiments of the invention, for two, three, or more comb elements to be arranged side by side in a direction extending vertically to the direction of combing. It may also be possible—for, e.g., the manufacture of circular combs in accordance with embodiments of the invention—to arrange two, three, or more comb elements in series in the direction of combing.

A method, in accordance with various embodiments of the invention, for the manufacture of a comb element for a combing device may include a number of operations. In a first operation, starting with, for example, an approximately cuboid raw material block made from high-alloyed steel, such as, e.g., chrome nickel steel, the slots separating the individual comb teeth from each other in the direction extending vertically to the direction of combing may be formed in the raw material. In a second operation, the form of the comb teeth may be removed from the raw material block in an aspect that is vertical to the direction of combing, while a connecting area, connecting the comb teeth with each other in the direction extending vertically to the direction of combing, as well as the fastening area of the raw material block, serving to fasten the comb element to the combing machine, are being preserved.

For the purpose of an efficient manufacture of comb elements and combing devices in accordance with embodiments of the invention, it may be advantageous to form two, three, or more slots simultaneously in the above-mentioned first operation. An efficient manufacture of comb elements or combing devices in accordance with embodiments of the invention may be ensured, while ensuring the required high manufacturing precision, if the first and/or second operation is carried out by spark erosion machining or spark erosion depth machining, with it being possible to use a multi-machining head for the simultaneous formation of two, three, or more slots in the raw material block and/or the simultaneous removal of two, three, or more saw teeth arranged in series in the direction of combing.

In various embodiments, it is possible to further accelerate the manufacturing method by processing the raw material block in the second operation from two opposite directions, respectively extending vertical to the direction of combing.

In the following, various embodiments of the invention are explained by reference to FIG. 1. FIG. 1 schematically illustrates a method for the manufacture of comb elements, which are suitable for the manufacture of top combs, in accordance with various embodiments of the invention. As is shown, a raw material block made from stainless high-alloyed steel, such as, e.g., chrome nickel steel, may be used as a basic raw material for the manufacturing process. The width b of this raw material block may be up to 300 mm and the height h of the raw material may be between 5 to 15 cm, inclusive, such as a height h of 10 cm. The depth t of the raw material block may be between 1 to 10 mm, inclusive, such as a depth t of 3 to 5 mm. In the manufacturing process, shown schematically in the drawing, the slots 12 may be removed from the raw material block 10 in a first operation via spark erosion machining using a multi machining head 20, with said slots 12 separating the comb teeth from each other in a direction P extending vertically to the direction of combing. In this process, three slots 12 may be simultaneously created by means of the multi machining head 20. In other embodiments of the invention, four or more slots 12 or 2 or fewer slots 12 may be produced simultaneously. In a second operation, profiles 50 may be simultaneously removed in an aspect directed vertically to the direction of combing, by means of machining heads 30 and 40, from the raw material block 10, from two opposite directions respectively extending vertically to the direction of combing. These profiles may exhibit, underneath the slots 12, a fastening area 54 connecting the combing teeth with each other, as well as saw teeth shaped combing teeth 52.

In both operations, spark erosion processes may be used. In contrast to conventional processes for the manufacture of combing devices for combing machines, such processes may allow for the manufacture of comb teeth 52 of any desired form, specifically any face form and teeth or tooth flanks of any profile. In this process, the flanks of the tooth-shaped teeth 52 may converge, for example, in sections, symmetrically in the direction of the tooth tips with respect to a plane extending vertically to the direction P. Embodiments of the invention are not restricted to the embodiments explained by reference to the drawing, however. Instead, the manufacture of circular comb sets by other processes in accordance with the embodiments of invention is also contemplated.

Multi machining heads may also be used in the manufacture of the tooth profiles in the second operation as well. Furthermore, the manufacture of comb teeth of any tooth shape is contemplated.

FIG. 2 illustrates a flowchart view of operations for manufacturing comb elements, in accordance with various embodiments of the invention. As illustrated, the operations may include forming, from a cuboid-shaped raw material block, slots in the raw material block, with the slots separating individual comb teeth from each other in a direction extending vertically to a direction of combing, block 202. In one embodiment, two, three, or more slots may be formed simultaneously. After forming the slots, the comb teeth may be removed from the raw material block in an aspect vertical to the direction of combing, with a connecting area connecting the comb teeth with each other in the direction extending vertically to the direction of combing, block 204. In some embodiments, the removing may further comprise processing, from two opposite directions, the raw material block, respectively extending vertically to the direction of combing. Further, in various embodiments, the forming and/or the removing may be performed using spark erosion machining or spark erosion depth machining. Lastly, the operations may include preserving a fastening area of the raw material block, block 206.

Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described, without departing from the scope of the embodiments of the present invention. This application is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is manifestly intended that the embodiments of the present invention be limited only by the claims and the equivalents thereof. 

1. A Combing device for a combing machine exhibiting at least one circular comb and at least one top comb, the combing device comprising: at least one comb element with at least two, three, or more comb teeth made in one piece, serving to engage in a fiber fleece, and arranged side by side in a direction extending vertically to a direction of combing.
 2. The Combing device of claim 1, wherein at least one of the comb teeth has a saw tooth shaped design with two tooth flanks extending parallel to the direction of combing and a tooth face connecting the tooth flanks and extending vertically thereto.
 3. The Combing device of claim 1, wherein the at least one comb element exhibits at least one fastening area made in one piece with the comb teeth and designed for the attachment of the at least one comb element to the combing machine.
 4. The Combing device of claim 1, wherein the at least one comb element has at least two, three, or more additional comb teeth arranged in series in the direction of combing.
 5. The Combing device of claim 1, wherein tips of the comb teeth, arranged side by side in the direction extending vertically to the direction of combing, are arranged on a straight line extending vertically to the direction of combing.
 6. The Combing device of claim 4, wherein tips of the additional comb teeth arranged in series in the direction of combing are arranged approximately on a circular arc.
 7. The Combing device of claim 1, wherein the at least one comb element is made at least in part from high-alloyed, stainless steel.
 8. The Combing device of claim 7, wherein the high-alloyed, stainless steel is chrome nickel steel.
 9. The Combing device of claim 1, wherein the combing device belongs to a top comb.
 10. The combing device of claim 1, wherein the combing device belongs to a circular comb.
 11. A Method comprising: forming, from a cuboid-shaped raw material block, slots in the raw material block, with the slots separating individual comb teeth from each other in a direction extending vertically to a direction of combing; and removing the comb teeth from the raw material block in an aspect vertical to the direction of combing, with a connecting area connecting the comb teeth with each other in the direction extending vertically to the direction of combing.
 12. The method of claim 11, further comprising preserving a fastening area of the raw material block.
 13. The method of claim 11, wherein said forming comprises forming two, three, or more slots simultaneously.
 14. The method of claim 11, wherein said forming and/or said removing are performed using spark erosion machining or spark erosion depth machining.
 15. The method of claim 11, wherein said removing further comprises processing, from two opposite directions, the raw material block, respectively extending vertically to the direction of combing. 